Halloween pumpkin out of Pallet wood

hey what's going on guys out some zucchini for mr. bill that welcome back to another week in the workshop if you're brand new the channel welcome we're just a bunch of DIY it's not afraid to try things not afraid to fail so if that's on that's along your side of the trail make sure you hit that subscribe button hit that notification belt so you know when these videos come out now without being put aside with Halloween right around the corner we wanted to make something that every homeowner can make as Halloween decor so what we're thinking is we're gonna call this the Pala wood jack-o'-lantern with that being said let's get into the video let's go to get started I picked up a pallet that I wasn't using specifically one that wasn't in terrible condition it's still pretty light in color now technique that I used for disassembling a pallet is usually the same I use a diamond diamond blade from Diablo to cut the outside nails out with the reciprocating saw and then I get the first nail down the middle mostly because the blade won't reach for the second one and then I will take a pry bar and I'll wiggle it back and forth allowing for the last nail to come out nine times out of ten this works exceptionally well then to get the remainder broken nails and whatnot out what I'll do is down the middle I'll flip it over take a hammer bust out the one nail that we didn't cut and then the one nail that is cut I would take a center punch hit it out and then pry it out as well and to save yourself some time for the ends we won't have to worry about prying those nails out we'll just use our chops our miter saw and cut the ends off just enough that you don't have them in the way now for this project we're gonna preserve as much of the pallet wood aging as we can but then the other part we need is straightening out to make it a little bit easier to work with to do so we're gonna throw some of these pallets on our jointer we're gonna do one edge and one flat surface not taking out more than about one or two sixteenths of an inch and like any other project when it comes to milling we do want to throw it on the table saw to create a matching parallel edge that way we can actually glue this project up accordingly so the big idea here is to create three individual hexagons and to do so we're gonna take our palo would mark it at six inches and create two both ended 30 degree cut - 30 degree cuts equals a 60-degree angle which is typical for your hexagon once you've gotten the first one down you can then use it as your measuring marker to kind of speed up your process to make sure all your pieces are consistent the same length now when we have created 18 identical pieces we're ready to glue up the way I do it I do the small angle the small side in the outside out being pallet wood the tape will stick kind of difficult so kind of bear with it I just used regular old duct tape once I was done I was able to flip it all over together lay down my wood glue I use tae-bong - like you guys have already heard in my previous videos and then I roll it up tape it up and very gently very carefully I bring a ratchet strap and I give it enough pressure to kind of give it a nice tight joint without breaking it apart or pushing all the wood glue out this would be a good time to use your tape measure to measure out to make sure that all the sides are roughly as even as possible while our hexagons are drying at this moment we're gonna take the opportunity to glue up the panels for the top and the bottom of our pumpkin and so Jessica any tables glue up take your time make sure the pieces are straight keep in mind because this is pallet wood it's not perfect types of wood even though we did mill it give it gentle enough pressure that it just lines up perfectly without squeezing out too much glue so the next day I came down and I removed all of our clamping mechanism that would be the ratchet straps and the duct tape I ensured both top and bottom edges of every hexagon was as even as possible it doesn't have to be perfect but as even as possible go over with a sander if you need to level it out then I apply the wood glue both on the tops and the bottoms of every tear stack them together and line them up as perfectly as I could keep in mind there will be some uneven unperfect edges but that's okay this is pallet wood and then use my F clamps to kind of sandwich and stack it and clamp it together at this point I'm using very light pressure because at this point this piece is pretty fragile it's not too bad but it's also not indestructible so just be gentle well that was drying I then took the panel though we did earlier slice didn't have to create a top and bottom piece of our pumpkin here and I set it on top then I traced the hexagon over to create a perfect match I also marked out with a 12 o'clock spots were to know that there's only one way it could fit once it was done we were ready to bring it to our band saw and cut this puppy out on my bandsaw I'm using a 3/4 range of blade specifically to make that cut as straight as possible once everything was cut out leaving as much pencil mark as I could I brought it over to my bench top belt sander to clean up as close to it as possible mostly because I want a nice tight fit when they get installed when he came down to installing the tops and the bottoms my strategy was simple leave the exposed weathered pallet wood facing to the top so when install on the bottom first I'm bound where the 12 o'clock points were sat at the shell right over it and hits it and installed flush took a damp rag wiped all the excess wood glue out use a little mallet to really seat it flush and be done with that part flip the back over and I did the same for the top really make sure you take your time to don't push it too much in because if you do well now you took a little bit of surface area away and it doesn't sit flush after we've got done drawing our goofy jackal interface we need to create a pilot hole to insert the jigsaw blade I'm using these box daredevil Spade bits this particular one is a little too big and I realized there's too much material to move being a hardwood so I switched over to a half inch spade bit and as you can see here it worked perfectly puncture right through it I'll leave a link in description I like these Spade bits because they have that little screw up front to make sure you get into it perfectly so then I've moved over to my jig saw I introduced it right into the pilot hole that we screwed out and we started kind of carving away our jack-o'-lantern for the holidays afterwards to clean up any of the tarry outs and kind of blend everything and I used 80 grit sandpaper to lightly blend everything together and get it ready for my bench top sander at the bench top sander I brought it to a 45 degree angle and I put a nice chamfer all along the entire edge to give it a three look when it came down to creating the type of lid I wanted to give the same lid as traditional pumpkin jack-o'-lanterns have work and it goes at an angle and it doesn't fall in so to accommodate this I took my Dremel multi-max and then a variety of the cutter heads and this particular one does the wood and metal so I kind of place it at an angle and I went and traced out the entire hexagons once the cut was all the way through I removed it and then just took some 80 grit sandpaper to clean everything up smooth flush and make it really nice looking for the pumpkin stem I used this old branch that I found in my backyard from a poplar tree so I took it to my bandsaw and i angled all these abstract cuts to kind of given more of an artsy kind of look after all the cuts were done I cleaned all the burn marks from the blade off on sander and then I took two one and a quarter inch screws and screwed it in from the bottom of the lid from my jack-o'-lantern once everything was lightly sanded I used this aerosolized satin clear coat to apply about three or four coats being for the outside I wanted to be protected once I was done it was ready to go to the front door and see how it looks and to give it the final finished look I used a 200 lumen husky LED magnet hook from the Home Depot it has magnets on the back and I just magnetized it to the screws that are right underneath this stem installed it and voila we're ready for Halloween well that is it for me this week thank you so much for watching this video guys it does mean the world to me if you liked this video make sure to hit that subscribe button tap the notification bell if you want to see more of the details on the tools that I use or follow me on my social media profiles I'll be down in the description down below tuning out this week we'll see you guys next week see ya